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Brick Kilns in India
J. S. KamyotraDelhi, India
kamyotra@yahoo.co.in
BRICK PRODUCTION IN ASIA
Bangla-
desh
India Vietnam Nepal Pakistan China
No. of brick - 1,40,000 10,000 700 >10,000 80,000
1. Very large and traditional industry in Asia
2. Mechanized and fully automated process for brick production is
used by Developed countries
No. of brick
units - 1,40,000 10,000 700 >10,000 80,000
Production in
billion 17.2 240-260 26.59 3.15 50 800-1000
Labor in '000 1000 9,000 NA NA 1500 5000
Population in
million 149.7 1210 176.5 18.6 176.7 1334
Brick use/
capita 115 215 151 169 283 750
INTERNATIONAL SCENARIO
INTERNATIONAL SCENARIO World over- Tunnel and Hoffman Kilns considered
as environment friendly EE technology and is being promoted
USA/ Europe – Natural gas fired Tunnel Kilns •High Initial cost (5-10 crores)
•Lack of Know-how
•Access to finance
•Hot environment inside
Hoffman kiln
China – Tunnel/ Hoffman Kiln
Vietnam – Coal fired Tunnel Kilns
Bangladesh – Hybrid Hoffman Kiln/ Tunnel Kiln
� Replacement with REBs (perforated bricks, hollow
bricks, bricks with internal fuel/ flyash bricks etc).
� Mechanization for clay preparation and molding
� Min. 20-30% savings in fuel and clay.
� In China, upto 80% of total fuel requirement mixed as
internal fuel and remaining 20% fuel used during firing
process – Emission reduction from kiln to a large
extent.
HOFFMAN KILN(Product Stationery and
Fire Moving)
Tunnel Kiln(Product Moving and
Fire Stationary)
INDIAN BRICK INDUSTRY
• Annual brick production growth: 5-10%
• 2nd largest brick producer after China.
• 74% of total production through BTKs and 21% through Clamps (100K).
Brick-making enterprises (all types)(no.) 1,40,000
Brick-making fuel used coal & biomassBrick-making fuel used coal & biomass
Annual brick production 240-260 billion
Coal/biomass consumption (million tce) 35-40
CO2 emissions (million t) 66
Clay consumption (million m3) 500
Total employment (million employees) 9-10
Distribution of different type of kilns in
India
BRICK MAKING PROCESS
• 99% brick production through hand molding
• Use of biomass/biomass waste/flyash with low CV as internal fuel in
some areas of Central/East and West zones.
• Clay preparation through pug mills/tractors with mixers in
Central/west/south India.
BRICK MAKING PROCESS: MANUAL
EXCAVATION & MOULDING
Ma
nu
al E
xc
ava
tion
Pre
pa
ratio
n
Ma
nu
al E
xc
ava
tion
Pre
pa
ratio
n
Ma
nu
al M
ou
ldin
g
Ta
ble
mo
uld
ing
BRICK MAKING PROCESS: MECHANICALB
ox
fee
de
r
Ex
ca
va
tion
Bo
x fe
ed
er
Ex
trud
ers
Ex
trud
ers
Ex
ca
va
tion
Bull’s Trench Kilns
EXISTING TECHNOLOGIES
FC
BT
K
HD
K
Ho
ffman
VS
BK
DOWNDRAFT/ CLAMP KILNS
SOURCES OF EMISSIONS
• Stack Emission
• Fugitive Emission
– During charging of fuel
– Crushing of coal
– Clay excavation– Clay excavation
– Loading and unloading of bricks
– Laying and removal of dust/ash layer ‘keri’ over brick setting
– Cleaning of bottom of trench/side flues
– During high winds
DIFFERENT TYPES OF FUELS USED A
ss
am
co
al
Co
tton
stra
w &
w
oo
d c
hip
s
As
sa
m c
oa
l W
oo
de
n c
hip
s,
mu
sta
rd &
co
tton
s
traw
Mu
sta
rd s
traw
C
otto
n s
traw
&
wo
od
ch
ips
FUEL ANALYSISType of Fuel Moisture
(%)
Ash
(%)
Volatile
(%)
Fixed Carbon
(%)
GCV
(Kcal/kg)
Coal
Assam Coal 0.96-2.99 11.03-26.46 22.84-37.71 37.06-49.88 4864-5603
Chandrapura
Coal
3.96-8.36 22.19-37.16 25.07-30.96 33.81-38.49 4077-4867
Indonesian Coal 13.5-16.7 2.82-15.16 42.31-46.29 28.85-35.6 5386-6316
Jharia Coal 0.31-1.48 34.47-46.89 15.83-26.85 33.78-50.06 3520-5034
Raniganj Coal 6.83-8.61 31.3-23.86 25.1-27.41 34.46-42.43 4607-5258Raniganj Coal 6.83-8.61 31.3-23.86 25.1-27.41 34.46-42.43 4607-5258
Biomass
Mustard straw 5.38-9.09 3.1-6.23 70.47-73.79 16.51-17.1 3998-4306
Rice Husk 5.63-19.4 17.4-23.89 48.26-55.95 14.53-14.92 3403-3471
Cotton straw 12.18 3.77 66.75 17.3 4219
Saw Dust 30.61 5.31 53.38 10.7 3235
Internal fuel
Katni Coal Dust 1.92 45.77 19.66 32.65 3336
Coal Rejects of
thermal Power
2.43 68.5 18.09 10.98 2049
FIRING PRACTICES AND PERFORMANCE OF FCBTKS IN FIVE ZONES
Parameters North East Zone
Central Zone West Zone SouthZone
Fuel Coal Biomass Coal Coal Biomass Coal Coal Biomass Coal
No. of columns 23-31 25-27 19-23 22 21-23 19-21 19-26 20-21 12-21.
Trench width (m) 8.2-11.6 9.5-9.94 7-8 7.8 7.6-8.2 6.4-10.4 6.4-8.7 7.8-8.54 3.6-6.4
Daily production capacity
32,000-40,000
36,000-40,000
16700-32000
28,000 19,000-
40,000
20,000-26,000
30,000-45,000
35,000-40,000
22,000-27,000
Firingtemperature (0C)
980-1050 940-1020
960-1070
880-980
900-980 960-1016 860-1016
925-973 720-850
SEC in MJ/Kg of fired brick
1.18-1.32 1.33-1.95 1.05-1.41 1.29 1.60-172 1.08-1.16 1.13-1.82 1.7-1.77 0.95-1.24
Stack Temperature (0C)
60-82 52-77 63-118 116 92-95 90-128 80-172 80-90 90-119
Velocity (m/s) 1.2-3.7 1.4-1.9 1.84-2.32 1.54 2.4-2.5 1.49-1.58 2.1-3.65 2.28-2.29 2.8-5.2
Volumetric flow rate (Nm3/hr)
11115-16040
14487-25938
7597-25938
20373 20610 9115-10600
11843-32284
24462-27984
9600-11100
SPM Charging
(mg/Nm3)
517-1375 268-382 124-865 619 294-330 500 122-422 122-147 75-364
Non-Charging 107-257 83-105 103-301 108 100-115 110-130 78-186 90 42-224
Integrated 102-688 140-374 162-742 566 169-271 357-450 90-384 96-146 55-298
SO2 (mg/Nm3) 10-595 5-8 34.1-563.3 10.5 7.9-3.1 13.1-23.6 5.2-943.2 18.3-52.4 0-437.5
CO (mg/Nm3) 193-1419 2275-2952 282-1748 205 495-1311 147-238 355-3579 2622-5026 269-880
CO2 % 0.6-2.85 2.4-2.6 1.2-2.4 1.2 0.7-1.7 1.7-15 1.0-2.4 1.7-2.0 1.5-2.1
Operating practice
North East Zone
Central Zone West Zone South Zone
Fuel Type Coal Biomass Coal Coal Biomass Coal Coal Biomass Coal
Size of fuel 1/2" to 2" Chopped
1” to 2”
1/2" to
3"
1" to 6" Chopped 1”
to2” size
Sa
me
as c
oa
l fired
kiln
Sam
e a
s c
oal fire
d k
iln
1" to 6" Chopped
1” to 2”
size
coal (1"
to 6")
Capacity of
feeding spoon
Heavy
feeding
using
spoon of
1.0-2.0 kg
With tokris
or vehngis
Spoon
size:
0.6-1.6
kg
Spoon
size 1.5-
2.5 kg
Tokri size:
25-30 kg &
vehngi size:
45-50 kg
Spoon of
size: 0.7-
2.0 kg
Tokri size:
25-30 kg
& vehngi
size: 45-
50 kg
With
tokris of
25-30 kg
capacity
No of rows being fed
Fuel feeding in two lines
Fuel feeding in one line
Fuel feeding in two
Heavy feeding in one line
Heavy feeding in one line
Fuel feeding in one or two
Heavy feeding in one line
fuel feeding done in
Sa
me
as c
oa
l fired
kiln
Sam
e a
s c
oal fire
d k
iln
lines lines two lines
Feeding frequencyCharging
5-10 mins Heavy 15-25 mins
7-12 mins
10-15 mins
15-25 mins 8-15 mins 15-25 mins 10-20 mins
Non-Charging 20-40 mins 20-40 mins 20-40 mins
30-50 mins
30-50 mins 30-50 mins 30-50 mins 30-50 mins
Remarks Thick smoke during
charging period
High surface
temperatures result in
self ignition of biomass at
surface only.
Coal crushers used
in some kilns
Thick smoke during
charging
High surface
temperatures result in self ignition of biomass at surface
only
Resulting in thick
smoke due to
charging
Due to feeding
coal lumps the
light greyishsmoke emitted
PERFORMANCE OF DESIGNS OF KILNS (OTHER THAN FCBTKs)
Parameters
FCBTK-Zig-
Zag
High Draft Kiln (HDK) VSBK Down Draft
Kiln
Hoffman Kiln
East Zone North Zone East Zone East /Central
Zone
(DDK) South Zone South Zone
No. of columns 15,000 bricks/
Chamber
18,000-
20,000 bricks/
chamber
10,500-
19,500 bricks/
chamber
440 bricks/
batch in 6layers
Batch process 4,000-5,000
bricks/
chamber
Trench width (m) 5.2-6.6 10-10.4 5.2-8 2.7
Daily production
capacity
20,000-30,000 30,000-
60,000
15,000-
28,000
6000-
8800
30,000
bricks /chamber
10,000-
12,000
Fuel Coal/pet coke/
biomass
Coal/pet
coke
Coal Coal Biomass Coal/fired
woodbiomass coke wood
Firing temperature (0C) 970-1015 970-1020 960-1050 870-915 820-850 650-810
SEC in MJ/Kg of fired
brick
0.92-1.06 1.08-1.10 1.07-1.15 0.9 2.80-3.14 1.21-1.52
Stack Temperature (0C) 118-163 107-109 54-146 152-179 181-252 118-128
Velocity (m/s) 2-2.83 3.4-3.99 2.01-3.37 2.55 2.8-4.3 2.04-2.86
Volumetric flow rate
(Nm3/hr)
7390-10008 11377-23845 8971-20761 4444-9285 5036-5498 8200-8500
SPM Charging
(mg/Nm3)
155 119-147.6 145.5-432 452 150-454.5 275-353
Integrated 128-134 49-116 149-316 314-405 75-359 200-315
SO2 (mg/Nm3) 393-469 1045-1053 13.1-615.7 84-89 118-975 5.2-7.9
CO (mg/Nm3) 95-158 332-1027 290-667 951-1440 4398-11309 2931-3518
CO2 % 2-2.4 1.8-1.9 1.27-2.4 0.6-1.1 8.1-11.9 4-4.4
Ctd.Parameters
FCBTK-Zig-
Zag
High Draft Kiln (HDK) VSBK Down Draft Kiln Hoffman
Kiln
Size of fuel Crushed coal Crushed coal
Crushed coal
Upto 1” For first 15-20 hrs fuel feeding rate is 30-400kg/hr
whereas for last 8-10 hrs fuel
feeding rate is 700-750 kg/hr
Capacity of feeding spoon
Spoon size: 0.175-0.3 kg
Spoon size : 0.25-1.0
kg
Spoon size : 0.25-0.5
kg
NA
No of rows being fed
6 chambers 6 chambers
2-3 chambers
Packed within
the brick settings
Total firing time 24-30 hrs
3 chambers
settings
Feeding frequency
Charging
10-15 mins or continuous Charging
7-10 minsor
continuous Charging
7-12 mins NA Continuous charging is done
Fire wood Charging
done for 8-10 mins
Non Charging 5-15 mins 12-15 min 10-12 mins 25-30 mins
Remarks thin smoke Thin smoke
during fuel Charging
Bloating of fired bricks due to
lumps of internal
fuel
Thick smoke during last 8-10 hrs of Charging
INFERENCES - PERFORMANCE OF KILNS IN DIFFERENT
ZONES
• FCBTKs/HDKs
• Trench width: 6.4-10.4 mtrs.
• Min. Production capacity: 22,000 bricks/day(trench width of 3.6m in South )
• High stack emissions/ thick smoke in kilns with shorter• High stack emissions/ thick smoke in kilns with shorter
combustion zone & poor operating practices.
• Excess Air levels of 400-1000% were observed during stack
emission monitoring.
• During fuel charging period SPM levels upto 1375 mg/Nm3
observed in kilns with poor operating practices.
• High CO levels observed in kilns using biomass as fuel.
SPECIFIC ENERGY CONSUMPTION (SEC) IN MJ/ KG OF FIRED BRICK
FCBTKs-Coal fired 0.95-1.82
FCBTK-Biomass fired 1.33 – 1.95
HDKs/FCBTK zig-zag 0.91-1.15 Better operating practicesHDKs/FCBTK zig-zag 0.91-1.15 Better operating practices
VSBK 0.90 Limited brick production
and high initial cost
Hoffman Kiln 1.21-1.52 Produce hollow block, roof
tiles
DDKs 2.8-3.14
Clamps 1.38-1.92
ENERGY BALANCEBasis: 1 Ton of clay brick
Sr. Parameters FCBTK FCBTK FCBTK HDK VSBK
No. (coal) (Biomass) (zig-zag)
Heat Input 1 Fuel (coal, biomass, etc.)
consumed
in MJ in % in MJ in % in MJ in % in MJ in % in MJ in %
1134- 1445 100 1364-
1772
100 1162 100 1038-
1097
100 834 100
Heat output1 Surface heat loss from kiln
(Top surface & side walls)
161-424 14-29 288-424 21-24 236 20 150-328 14-30 27 3.2
2 Heat loss in dry flue gas 35-107 3-7 51-153 3.7-8.6 71 6.1 22-82 2-7.5 205 24.6
*Heat required for irreversible chemical reaction & losses such as trench bottom, periodic
heating and cooling of kiln structure & due to unburnt carbon in ash
3 Heat required for removing
the mechanically held water in
green bricks
36-339 3-23 33-244 2.4-13.8 186 16 102-169 10-15 68 8.2
4 Heat loss due to hydrogen &
moisture in fuel
40-80 3-5 98-132 7.2-7.5 46 4 33-49 3.2-4.5 15 1.8
5 Heat loss due to partial
conversion of C to CO
5-28 0.5-2 21-75 1.5-4.2 4 0.3 23-37 2.2-3.4 29 3.5
6 Sensible heat loss in unloaded
bricks
4-20 0.3-1.4 20-26 0.5-1.5 23 2 27-60 2.6-5.5 47 5.6
7 Other heat component* 477-960 42-66 442-1250 32-70 596 51 440-613 42-56 443 53.1
PERFORMANCE EVALUATION OF APCD IN FCBTKs
The particulate removal efficiency of different
design of Gravity Settling Chamber (GSC)
generally ranged from 20-63%. The stack
emission levels at inlet of GSC vary between
592-1495 mg/Nm3.
General ambient air QUALITY-brick kilns
• Impacts not continuous or long term because brick kilns are
seasonally operated and operations is cyclic in nature.
• Ambient SO2 & NOx levels rarely exceeded 25 µg/m3
• The NOx emissions from kiln stacks were also very low and hence• The NOx emissions from kiln stacks were also very low and hence
its impact on GLCs, the impact of kiln emissions would be
insignificant.
AIR POLLUTANT DISPERSION MODELING
• To assess the maximum impact of stack
emissions (SO2 & SPM) on Ground Level
Concentration (GLC).
• To formulate stack height guidelines for ensuring• To formulate stack height guidelines for ensuring
the safe impact levels in the context of
prescribed Ambient Air Quality Standards.
• To recommend siting guidelines for brick kilns.
EMISSION DISTRIBUTION PATTERNS IN
NORTH ZONE USING ISCST3 MODEL:
500
1000
1500
2000
500
1000
1500
2000
-2000 -1500 -1000 -500 0 500 1000 1500 2000
Distance (m)
-2000
-1500
-1000
-500
0
Maximum GLC- 21.94 µg/m3 ,
co-ordinates (200,-200)
SPM EMISSIONS
-2000 -1500 -1000 -500 0 500 1000 1500 2000
Distance (m)
-2000
-1500
-1000
-500
0
Maximum GLC-5.13 µg/m3 ,
co-ordinates (400,-200)
SO2 EMISSIONS
Emission Factor
• The emission factor for SPM & Sulphur Dioxide is mainly due to quality offuel and its feeding & operating practices.
• In case of coal fired brick kilns the average emission factor for SPM was inthe range of 0.79 to 1.85 g/kg of fired bricks in the three zones namelyNorth Zone, East Zone and Central Zone wherein brick firing temperature isabove 9500C.
• Low average emission factor of 0.57g/kg observed in the South Zone whichis mainly due to low firing temperature (around 8500C) and feeding of biglumps of coal after longer intervals. Moreover the quality of brick is alsocomparatively inferior to the bricks produced in North, East and Centrallumps of coal after longer intervals. Moreover the quality of brick is alsocomparatively inferior to the bricks produced in North, East and CentralZones.
• FCBTK using biomass has lesser emission factors as compared to coal firedFCBTKs (SPM emission factor in the range of 0.78 to 1.19 g/kg of firedbricks).
• The average emission factor for SPM in FCBTK with zigzag firing was 0.37g/kg of fired bricks due to longer combustion zone in comparison toconventional FCBTKs and good combustion practices adopted in theprocess. The emission factor is almost comparable with High Draft Kiln.
Ctd...
• The emission factor for SPM in High Draft Kiln were in the range of 0.21to 1.12g/kg of fired brick due to efficient burning of fuel by adoptinggood firing practices.
• The emission factors for SPM in VSBK was 1.86 to 2.6 g/kg of firedbricks.
• The biomass fired DDK and Hoffman Kiln in South Zone has emissionfactor of 0.38 to 1.82g/kg of fired bricks.
• Emission factor for SO2 were mainly due to sulphur content in the fuelsused. Low emission factors of 0.03 to 0.23g/kg of fired bricks wereused. Low emission factors of 0.03 to 0.23g/kg of fired bricks wereobserved in biomass fired brick kilns. Whereas, in case of coal firedkilns it varied from 0.04 to 0.67 g/kg of fired bricks.
• The average emission factor for NOx were generally low and was foundin the range of 0.03 to 0.32g/kg of fired bricks.
PROPOSED ACTION PLAN
• Two Fold Strategy proposed:
1. Long Term Measures
2. Short term Measures
PROPOSED ACTION PLAN
1. Long Term Measure:
• Effective policies and regulations required forimplementing energy efficient technologies likeTunnel Kiln, Hoffman Kilns etc.
• Need for establishing the demand/market forresource efficient products like hollow andNeed for establishing the demand/market forresource efficient products like hollow andperforated bricks, and limiting the production ofsolid bricks in phases.
• The technologies being capital intensive, requiresmechanism for financial support before itsreplication on large scale.
Short Term Measures
a) Adoption of improved feeding, firing and operating practices in existing
FCBTKs
b) Retrofitting of kiln and converting into High Draft Kiln/ Fixed Chimney Bull’s
Trench Kiln with zig-zag firing.
c) Extensive Capacity Building Program for ‘a’ above.
TECHNOLOGY SELECTION
• Need for initiatives for promotion of EE technologies
while framing new Regulations for:
– Reducing the emissions from brick making process
– Conserving resource materials and
– Reducing carbon footprint.Reducing carbon footprint.
• FCBTK is the most prevailing technology, producing
74% of the country’s brick production.
• Need based changes have been incorporated in brick
production technology which has improved its EE.
• Use of locally available biomass in FCBTKs has also
picked up especially in North and Central Zone.
TECHNOLOGY SELECTION.. Inferences
• However, the smoke emission from the kiln stack,
especially during charging time is a cause of
concern which can be reduced by only adopting
better feeding, firing & operating practices.
• In India, High Draft Kilns (HDKs) and Vertical Shaft• In India, High Draft Kilns (HDKs) and Vertical Shaft
Brick Kilns (VSBKs) are comparatively more energy
efficient technologies. constraints are
– need for electricity/power back up in case of HDKs and
– high initial cost/ low production & non availability of skilled
manpower in case of VSBK, these technologies has not
been replicated on large scale
Existing Standards for Brick KilnsSr.
No.
Industry Parameter Standards
1 2 3 4
74 Brick
Kilns i. Bull’s Trench Kiln
(BTK) Category* Limiting concentration in mg/Nm3
Particular matter
Small 1000
Medium 750
Large 750
Stack height minimum (metre)Stack height minimum (metre)
Small 22 or induced draft fan operating with minimum draft of 50 mm
WG with 12 metre stack height.
Medium 27 or induced draft fan operating with minimum draft of 50 mm
WG with 15 metre stack height.
Large 30 or induced draft fan operating with minimum draft 50 mm WG
with 17 metre stack height.
*Category Trench width
(m)
Production (bricks/day)
Small BTK <4.50 Less than 15,000
Medium BTK 4.50-6.75 15000-30000
Large BTK above 6.75 Above 30000
74 Brick Kilns (ii) Down-Draft Kiln (DDK) Category** Limiting concentration in mg/Nm3
Particular matter small/medium/large 1200
Stack height minimum (metre)
Small 12
Medium 15
Large 18
**Category Production (bricks/day)
Small DDK Less than 15000
Medium DDK 15,000-30,000
Large DDK Above 30,000
74 Brick Kilns (iii) Vertical Shaft Kiln (VSK)
Category** Limiting concentration in mg/Nm3
Particular matter
small/medium/large
250
Stack height minimum (metre)
Small 11 (at least 5.5 m from loading platform)
Medium 14 (at least 7.5 m from loading platform)
large 16 (at least 8.5 m from loading platform)
**Category No. of shafts Production (bricks/day)**Category No. of shafts Production (bricks/day)
Small VSK 1-3 Less than 15000
Medium VSK 4-6 15,000- 30,000
Large VSK 7 or more Above 30000
1. Gravitational Settling Chamber along with fixed chimney of appropriate height shall be provided for all Bull’s
for all Bull’s Trench kilns.
2. One chimney per shaft in Vertical Shaft Kiln shall be provided. The two chimneys emanating from a shaft shall
either be joined (at the loading platform in case of brick chimney or at appropriate level in case of metal
chimney) to form a single chimney.
3. The above standards shall be applicable for different kilns if coal, firewood and / or agricultural residues are
used as fuel.”
PROPOSED EMISSION
STANDARDS
FIXED CHIMNEY BULL’s TRENCH
KILN (FCBTK), KILN (FCBTK),
HIGH DRAFT KILN (HDK) &
HOFFMAN KILN
Guidelines for better fuel charging &
operating practices in and siting of
Bull’s Trench Kilns and Clamp KilnsBull’s Trench Kilns and Clamp Kilns
IMPROVED FUEL CHARGING & OPERATING PRACTICES(For improving the combustion efficiency and reduce emissions)
• The coal charging in Bull’s Trench Kilns should be properly graded
and maximum size of coal charged should be limited to 20 mm.
• Fuel charging in Bull’s Trench Kilns should be done in minimum 3
rows of brick setting at a time in case of coal and in minimum 2
rows of brick setting at a time in case of firewood and agriculturalrows of brick setting at a time in case of firewood and agricultural
residues.
• Minimum 3 fuel charging shall be done every hour in Bull’s Trench
Kilns.
• Internal fuel, such as powdered coal, flyash etc. should be used by
mixing with clay during brick making in Bull’s Trench Kilns and
clamp brick kilns.
PROCESS EMISSION CONTROL
• Crushing of coal should be done in enclosed equipment/ area to
avoid process emissions.
• Following measures be adopted to control dust emissions due to
airborne ash from the top of brick settings:
• Raising a 2 feet wind breaker wall along the outer trench wall
of bull’s trench kilns.
• Covering of the top ash layer in the preheating zone with• Covering of the top ash layer in the preheating zone with
sheet in bull’s trench kilns.
• The approach road and the road around brick kiln should be
paved/stabilized.
• Water should be sprinkled frequently over roads around brick kiln
and over the ash layer before its removal and transfer.
• Two or three rows of trees should be planted along the outer
periphery of kiln area.
PROCESS IMPROVEMENT
• Use of Temperature gauge in firing zone, flue duct and chimney tomonitor and control combustion process.
• Use of double walled insulated feedhole covers packed withinsulation material such as ceramic or asbestos fibers to preventheat loss from fuel charging holes bull’s trench kilns.
• Double walled wicket with kiln ash filled in between Bull’s TrenchKilns instead of conventional single brick wicket wall with brick onedge which results in leakage.edge which results in leakage.
• Closing of side flue ducts with brick wall (1 ½ brick thick) plasteredwith a mix of sand clay and cow dung bull’s trench kilns oralternatively, shunt system should be used for transferring the gasfrom side flues to central flue, connected with chimney.
• Minimum 7 inch thick brick kiln ash layer over the brick settingbull’s trench kilns to provide heat insulation.
• Placement of fuel in multi-layers during brick stacking in clampkilns to reduce emissions and to produce better quality bricks
NORMALISATION OF EMISSION
STANDARDS IN FCBTK/HDK
• The air supply in a (FCBTK) drawn through the cooling/ fired brick
withdrawal zone has following role:
• Assist in the combustion of the fuel
• In addition to the combustion, air is needed to carry forward the heat
through different zones for transferring the heat (i.e. cooling of hot
fired bricks and drying/ pre-heating freshly set green bricks beforefired bricks and drying/ pre-heating freshly set green bricks before
combustion)
Normalisation of Emission Standards in FCBTK/HDK
Therefore, in addition to air required for combustion, excess air is
required for transferring of heat to different zones. Various authors
have indicated the total quantity of air as:
• 6-7 times the quantity of air required for the combustion of fuel
(Alfred B. Searle, 1956)
• 500% excess air is required in a continuous kiln (Tim Jones, 1996)• 500% excess air is required in a continuous kiln (Tim Jones, 1996)
Better practices
• Fuel Storage
• Size of Coal
• Fuel quality
• Fuel feeding
• Kiln Maintenance• Kiln Maintenance
• Use of internal fuel
• Fugitive Emissions
• Monitoring
• Protection to workers health
Fuel Storage
• The coal should be stacked on a raised platform with
pucca flooring and proper drainage arrangements.
• Coal should preferably be stored under shed with
proper ventilation
• The height of coal stack should not be more than 1.5• The height of coal stack should not be more than 1.5
meter otherwise it will loose its heat value due to self
ignition under intense heat and pressure.
Size of Coal • The size of coal should be such that the coal should either be
completely burnt or atleast should have caught fire before thenext round of feeding. Hence the coal size should be betweenpowder to ¾ inch i.e. properly graded coal. This would help inuniform brick quality as the powdered coal ignites immediatelyon feeding thereby releasing heat to the top layer of bricksetting. Whereas large sized coal particles release heat at thebottom of brick setting.setting. Whereas large sized coal particles release heat at thebottom of brick setting.
• Small sized coal improves air-fuel mixing thus accelerating therate of combustion. Appropriate size of coal can be obtained byscreening/ crushing of large sized coal.
• The crushing of coal leads to fugitive emissions. It is advised thatcoal crushing should be done in enclosed area with high walls soas to avoid cross currents.
•
Fuel quality
• Use of coal with high ash content will not only lead tohigh stack emission but will also pose a problem ofhandling of ash. It is, therefore, recommended that coalwith ash content more than 35% should be avoided.
• Coal with high sulphur content (more than 2%) shouldnot be allowed to use in brick kilns especially in thenot be allowed to use in brick kilns especially in theareas in the vicinity of orchards or flower bearing crops.
•
Fuel feeding
• Feeding of fuel in more number of lines would increase
the length of firing zone and would result in more efficient
combustion thereby reduction in stack emissions. Besides
this the SEC of brick kiln would also improve.this the SEC of brick kiln would also improve.
Kiln Maintenance• Constructing double walled wicket with rapish/keri in
between. The conventional practice of single brick wicket
wall with brick on edge results in leakage and hence should
be avoided.
• Closing side flues with brick wall (1 ½ brick thick) plastered
with a mix of sand clay and cow dung.with a mix of sand clay and cow dung.
• Using double walled insulated feedhole covers. The existing
feed hole covers are made of single layer steel plate. The
insulated feed hole covers consists of double walled steel
plates packed with insulation material such as ceramic or
asbestos fibres.
• Providing a minimum ash/keri thickness of 7 inch over the
brick setting.
• It is also observed that the kiln structure is partially/fullybelow the ground level in many States. And even the sidewalls/base of the kiln is unlined. During rainy season, thetrench of brick kiln use to be filled with water. As a result,during first cycle of firing, additional fuel to the extent of40-50% is consumed in order to evaporate the excessmoisture present in the kiln structure, thereby emittingdark smoke from the kiln chimney. Besides this the qualityof bricks is also severely affected during first cycle. It is,therefore, recommended that:therefore, recommended that:• The kiln should always be above the ground level with proper
drainage facility.
• The kiln structure should preferable be covered by providing ashed over the kiln portion. Provision of shed over kiln wouldsave at least 20-30 tons of coal every first cycle. The shed willhave a payback period of around 4-5 years depending upon theweather of particular location.
• Providing shed over the kiln would also improve the ambience ofthe area and provide shade to the workers working in the kiln.
Use of internal fuel
• Internal fuel such as ash with carbon, powdered coal or other
waste with fuel value should be used in clay. Better mixing of
fuel in clays can be achieved using mechanical means. Use of
internal fuel will reduce the feeding requirement thus leading
to reduced emissions.
Fugitive Emissions• During summer winds/ storms, the ash layer over the top of brick settings,
become airborne resulting in fugitive emissions. To minimise this, windbreakers should be raised along the outer trench wall of brick kiln byconstructing two feet high brick wall.
• Provision of shed over the kiln structure will also reduce the fugitiveemissions.
• Water should be sprinkled over the keri/ ash layer before its removal andtransfer.transfer.
• The coal crusher should be installed in an enclosed area with minimum 6’high walls.
• Brick paved/earthen stabilized roads shall be constructed along the outerperiphery of brick kiln and approach roads. The water should be sprinkledfrequently over these roads.
• Two or three rows of trees with thin leaves should be planted along theouter periphery of kiln area.
• The ash layer in the preheating zone can be covered with plasticsheet/tirpal.
Monitoring• Since the process of loading, unloading and firing system is
totally manual and its performance and efficiency depends
on the efficiency and skill of the workers, it is utmost
important to monitor the activities, especially the feeding
and operating practices in the kiln by using
instrumentation, installing monitoring gadgets.
• It should be made mandatory for a kiln owner to employee a
supervisor with minimum 10+2 qualification who will keep the log of
temperature in the firing zone, in the side flue and chimney.
• A temperature gauge shall be installed in the kiln chimney to
monitor the temperature of flue gas.
Protection to workers health
• Covering of the kiln top with a continuous layer of
bricks or tiles.
• A full face mask is to be provided to workers to protect
their eyes, ears and nose.
• Hand gloves are to be provided to workers to protect• Hand gloves are to be provided to workers to protect
their hands from ill effects of coal handling and also
from hot flue gases coming out of fire hole during the
charging.
• Special coat/apron and shoes are to be provided to the
workers for their protection against these hazards.
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